Roofing method

ABSTRACT

The first step of the method is providing a roofing laminate including an upper component of a reinforced single ply synthetic membrane. The roofing laminate includes a lower component of a reinforced single ply synthetic membrane. The roofing laminate includes an intermediate component of synthetic reinforcement material. The next step of the method is attaching the intermediate component intimately and entirely with the upper and lower components. The final step is coupling the laminate to a building.

BACKGROUND OF THE INVENTION

The present application is a continuation-in-part of co-pending U.S. patent application Ser. No. 12/589,195 filed Oct. 20, 2009 which, in turn, is a continuation-in-part of U.S. patent application Ser. No. 12/070,788 filed Feb. 21, 2008, the subject matter of which applications is incorporated herein by reference.

SUMMARY OF THE INVENTION Field of the Invention

The present invention relates to a roofing method and more particularly pertains to fabricated of ecologically preferred materials and devoid of energy consuming constituents.

In view of the foregoing disadvantages inherent in the known types of roofing methods and systems of known designs and configurations now present in the prior art, the present invention provides an improved roofing method. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved roofing method which has all the advantages of the prior art and none of the disadvantages.

To attain this, the present invention comprises a roofing method. The method includes the step of providing a roofing laminate. The roofing laminate includes an upper component of a reinforced single ply synthetic membrane. The roofing laminate includes a lower component of a reinforced single ply synthetic membrane. The roofing laminate includes an intermediate component of synthetic reinforcement material. The method includes the step of attaching the intermediate component intimately and entirely with the upper and lower components. The method includes the step of coupling the laminate to a building.

There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions and method steps insofar as they do not depart from the spirit and scope of the present invention.

It is therefore an object of the present invention to provide a new and improved roofing method which has all of the advantages of the prior art roofing methods of known designs and configurations and none of the disadvantages.

It is another object of the present invention to provide a new and improved roofing method and system which may be easily and efficiently manufactured and marketed.

It is further object of the present invention to provide a new and improved roofing method and system which is of durable and reliable constructions.

An even further object of the present invention is to provide a new and improved roofing method and system which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such roofing method economically available to the buying public.

Lastly it is object of the present invention is to provide a roofing method utilizing ecologically preferred materials and devoid of energy consuming constituents.

These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

FIG. 1 is a perspective illustration of a roofing method constructed in accordance with the principles of the present invention with parts broken away to illustrate certain internal constructions.

FIG. 2 is a perspective illustration of the laminate of the roofing method shown in FIG. 1, the laminate being in roll form prior to installation.

FIG. 3 is a perspective illustration of the roofing method with heat welding only.

FIG. 4 is a perspective illustration of the roofing method with mechanical fasteners and heat welding.

FIG. 5 is a front elevational view of a portion of a roofing method constructed in accordance with an alternate embodiment of the invention.

FIG. 6 is a cross sectional view taken along line 6-6 of FIG. 5.

FIG. 7 is a perspective illustration of the roofing method shown in FIGS. 5 and 6 following installation.

The same reference numerals refer to the same parts throughout the various Figures.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference now to the drawings, and in particular to FIG. 1 thereof, the preferred embodiment of the new and improved roofing system embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.

The present invention, the roofing system 10 is comprised of laminate.

First provided is a building 14. The building has an upper surface. The upper surface has a roof 16. The roof is slanted. In this manner rain falling on the roof will then fall to the ground.

A roofing laminate 18 is provided. The roofing laminate is mechanically secured to the roof of the building. The roofing laminate includes an upper component 20. The upper component is fabricated of a reinforced single ply membrane. The reinforced single ply membrane is chosen from the class of reinforced single ply membranes. The class of reinforced single ply membranes includes thermoplastic polyolefin and ethylene propylene diene monomer rubber and polyvinyl chloride. The upper component has a thickness of between about 0.010 inches and 0.30 inches. The upper component, optionally, has an upper surface with embossing to provide an eye-appealing textured appearance.

The roofing laminate includes a lower component 22. The lower component is fabricated of a reinforced single ply membrane. The reinforced single ply membrane is chosen from the class of reinforced single ply membranes. The class of reinforced single ply membranes includes thermoplastic ethylene propylene diene monomer rubber and polyvinyl chloride. The upper component has a thickness of between about 0.010 inches and 0.30 inches.

The roofing laminate includes an intermediate component 24. The intermediate component is fabricated of a woven reinforcement material. The intermediate component is integrally formed with the upper and lower components. The intermediate component has a thickness of between about 0.010 inches and 0.30 inches. The laminate has a thickness of at least 0.045 inches.

Provided next is a securement assembly. The securement assembly functions for coupling the laminate to the roof. The securement assembly is chosen from the class of securement assemblies including mechanical fasteners 28, heat welding 30 and a combination of mechanical fasteners and heat welding. The mechanical fasteners are chosen from the class of mechanical fasteners including nails and staples and screws. Nails are the preferred mechanical fasteners. Heat is preferably applied to the entire surface of the laminate by a heat gun 32 following initial securement by the mechanical fasteners. The preferred securement assembly thus includes nails and heat welding.

The laminate with adhesive material and cover sheet are in the form of a roll 34. The roll is between about 50 feet and 100 feet in length and about 12 inches in width for transporting and storage prior installation and use.

The laminate has a linear upper edge and a parallel lower edge. The laminate has spaced slots 36. The spaced slots are provided perpendicular to the edges and spaced about 12 inches apart. The slots extend from the lower edge to about 50 percent of the distance to the upper edge. In this manner a non-slotted upper extent of a lower laminate is covered by a slotted lower extent of a higher laminate. Further in this manner the slots provide an appearance of individual shingles.

Provided last is a non-asphaltic underlayment 40 of compatible material in sheet form. The non-asphaltic underlayment is secured to the roof of the building and receives the laminate.

Note the alternate embodiment of FIGS. 4-6. Laminate 104 is provided. The laminate is in the form of a rectangle. The rectangle is about 1 foot by about 3 feet. The laminate has a linear upper edge. The laminate has a parallel lower edge. The laminate has spaced slots 106. The spaced slots are provided perpendicular to the edges and located about 12 inches apart. The slots extend from the lower edge to about 50 percent of the distance to the upper edge. In this manner a non-slotted upper extent of a lower laminate is covered by a slotted lower extent of a higher laminate. Further in this manner the slots provide an appearance of individual shingles.

A securement assembly is also included. The securement assembly of the alternate embodiment is essentially the same mechanical fasteners and/or heat welding as described above with respect to the primary embodiment.

The shingle units are made from thermoplastic polyolefin, ethylene propylene diene monomer rubber or polyvinyl chloride membrane and may come in either continuous roll form or individual units. The single ply shingles may be either mechanically fastened or produced in a self-adhering format.

The present invention also includes a roofing method. From a broad standpoint, the invention includes a totally synthetic system which includes synthetic shingles above and a synthetic laminate below. The method also includes the step of providing a roofing laminate. The roofing laminate includes an upper component of a reinforced single ply synthetic membrane. The roofing laminate includes a lower component of a reinforced single ply synthetic membrane. The roofing laminate includes an intermediate component of synthetic reinforcement material. The method includes the following step of attaching the intermediate component intimately and entirely with the upper and lower components. Lastly, the method includes the step of coupling the laminate to a building.

From a more specific standpoint, the invention is a roofing method fabricated of ecologically preferred materials and devoid of energy consuming constituents. The method includes the steps of:

providing a building having an upper surface with a roof, the roof being slanted whereby rain falling on the roof will then fall to the ground;

providing a roofing laminate, the roofing laminate including an upper component and a lower component and an intermediate component between the upper and lower components, the intermediate component having a planar upper surface and a planar lower surface;

the upper component being a reinforced single ply membrane chosen from the class of reinforced single ply membranes including thermoplastic polyolefin and ethylene propylene diene monomer rubber and polyvinyl chloride, the upper component having a thickness of between about 0.010 inches and 0.30 inches, the upper component having a planar lower surface;

the lower component of a reinforced single ply membrane chosen from the class of reinforced single ply membranes including thermoplastic polyolefin and ethylene propylene diene monomer rubber and polyvinyl chloride, the upper component having a thickness of between about 0.010 inches and 0.30 inches, the lower component having a planar upper surface;

the intermediate component of a woven reinforcement material, the intermediate component integrally formed with the upper and lower components and having a thickness of between about 0.010 inches and 0.30 inches, the laminate having a thickness of at least 0.045 inches, the intermediate component having a planar upper surface and a planar lower surface;

attaching the lower surface of the upper component to the upper surface of the intermediate component with the lower surface of the upper component in intimate and direct contact throughout the entire extent of the upper surface of the intermediate component;

attaching the upper surface of the lower component to the lower surface of the intermediate component with the upper surface of the lower component in intimate and direct contact throughout the entire extent of the lower surface of the intermediate component;

providing a non-asphaltic underlayment of a compatible material, the underlayment having an upper surface and a lower surface;

coupling the underlayment to the roof of the building with the lower layer of the underlayment on the roof of the building; and coupling the roofing laminate to upper surface of the underlayment.

The benefits of the present invention include:

1. Very high solar reflectance index;

2. Exceptional resistance to solar UV, ozone and oxidation;

3. Petroleum free;

4. Provides clean storm water runoff;

5. Outstanding puncture resistance;

6. Single ply is LEED compliant and an energy star rated roof product;

7. VOC free;

8. Able to withstand high wind velocities; and

9. Highly fungus resistant.

The prevent invention includes these safety warnings:

1. It is suggested that installers wear UV resistant sunglasses and sunscreen to protect from solar reflectivity; and

2. Use precaution against slip and fall hazards.

As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.

With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. 

What is claimed as being new and desired to be protected by Letters Patent of the United States is as follows:
 1. A roofing method utilizing totally synthetic materials which includes the step of: providing a roofing laminate, the roofing laminate including an upper component of a reinforced single ply synthetic membrane, the roofing laminate including a lower component of a reinforced single ply synthetic membrane, the roofing laminate includes an intermediate component of synthetic reinforcement material; attaching the intermediate component intimately and entirely with the upper and lower components; and coupling the laminate to a building.
 2. The roofing method as set forth in claim 1 wherein: the upper component includes a single ply membrane chosen from any one material selected from the group consisting of single ply membranes including thermoplastic polyolefin and ethylene propylene diene monomer rubber and polyvinyl chloride, the upper component having a planar lower surface; the lower component includes a single ply membrane chosen from any one material selected from the group consisting of single ply membranes including thermoplastic polyolefin and ethylene propylene diene monomer rubber and polyvinyl chloride, the lower component having a planar upper surface; the intermediate component includes reinforcement material having a planar upper surface and a planar lower surface; attaching the lower surface of the upper component to the upper surface of the intermediate component with the lower surface of the upper component throughout the entire extent of the upper surface of the intermediate component; and attaching the upper surface of the lower component to the lower surface of the intermediate component with the upper surface of the lower component throughout the entire extent of the lower surface of the intermediate component.
 3. The method as set forth in claim 1 and further including the step of: providing synthetic shingles; and coupling the synthetic shingles to the building above the laminate.
 4. A roofing method fabricated of ecologically preferred materials and devoid of energy consuming constituents comprising, in combination: providing a building having an upper surface with a roof, the roof being slanted whereby rain falling on the roof will then fall to the ground; providing a roofing laminate, the roofing laminate including an upper component and a lower component and an intermediate component between the upper and lower components, the intermediate component having a planar upper surface and a planar lower surface; the upper component being a reinforced single ply membrane chosen from the class of reinforced single ply membranes including thermoplastic polyolefin and ethylene propylene diene monomer rubber and polyvinyl chloride, the upper component having a thickness of between about 0.010 inches and 0.30 inches, the upper component having a planar lower surface; the lower component of a reinforced single ply membrane chosen from the class of reinforced single ply membranes including thermoplastic polyolefin and ethylene propylene diene monomer rubber and polyvinyl chloride, the upper component having a thickness of between about 0.010 inches and 0.30 inches, the lower component having a planar upper surface; the intermediate component of a woven reinforcement material, the intermediate component integrally formed with the upper and lower components and having a thickness of between about 0.010 inches and 0.30 inches, the laminate having a thickness of at least 0.045 inches, the intermediate component having a planar upper surface and a planar lower surface; attaching the lower surface of the upper component to the upper surface of the intermediate component with the lower surface of the upper component in intimate and direct contact throughout the entire extent of the upper surface of the intermediate component; attaching the upper surface of the lower component to the lower surface of the intermediate component with the upper surface of the lower component in intimate and direct contact throughout the entire extent of the lower surface of the intermediate component; providing a non-asphaltic underlayment of a compatible material, the underlayment having an upper surface and a lower surface; coupling the underlayment to the roof of the building with the lower layer of the underlayment on the roof of the building; and coupling the roofing laminate to upper surface of the underlayment. 